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2A1-6: Plant Maintenance > Objective 02: Approaches to Maintenance > Flashcards

Objective 02: Approaches to Maintenance Flashcards

1
Q

Total Productive Maintenance (TPM)

A

A comprehensive structured approach to ensure reliability and develop a standardized maintenance program that applies to all aspects of maintenance

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2
Q

When is TPM appropriate to be used?

A

When a company wants a structured and formal means of improving maintenance and reliability

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3
Q

When is TPM not an appropriate means of improving maintenance and reliability?

A

When there are specific known area that need improvement

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4
Q

What are some approaches to maintenance management that focus on risk management?

A
  1. Reliability Centered Maintenance
  2. Risk-Based Inspection
  3. Statistical Risk Assessment
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5
Q

What are 2 major categories of maintenance?

A
  1. Preventive

2. Corrective

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6
Q

Preventive Maintenance

A

The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning of an item

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7
Q

Corrective Maintenance

A

The maintenance carried out after fault recognition and intended to put an item into a state in which it can perform a required function

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8
Q

What are 3 types of Preventive Maintenance?

A
  1. Condition monitoring and inspection
  2. Functional testing or failure finding
  3. Interval-based repair or replacement
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9
Q

Emergency Maintenance

A

Corrective Maintenance that has to be done immediately

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10
Q

When is the most efficient time to perform maintenance?

A

Just before failure

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11
Q

How is it possible to perform efficient maintenance?

A
  1. There is a good way to monitor the equipment

2. There is convenient time to perform it

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12
Q

What are some examples of Condition Monitoring?

A
  1. Monitoring oil filter differential pressure and replacing the filter when a pre-determined pressure is reached
  2. Inspecting a pressure vessel for corrosion or erosion by visual inspection or by measuring wall thickness using ultrasonic inspection
  3. Performing oil analysis and replacing the oil when certain levels of contaminants are reached
  4. Doing vibration monitoring on rotating equipment, e.g. a pump, and replacing it when the vibration exceeds a certain value
  5. Using human senses to detect changes in sound, oil leakage, or other signs of deterioration
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13
Q

What does Functional Testing look for?

A

Hidden Failures

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14
Q

Hidden Failure

A

A failure that does not become evident when it occurs because the function is not required at that time, or is only activated intermittently

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15
Q

When is Functional Testing especially relevant?

A

For protective devices that are not needed very often

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16
Q

What are some examples of Functional Testing?

A
  1. Checking an overspeed switch to make sure it trips at the correct speed
  2. Verifying the correct operation of a pressure switch
  3. Starting a backup generator on a monthly basis to verify its operation
  4. Exercising shutoff valves to prevent them from seizing up
  5. Checking the spare tire on your car
17
Q

Interval-Based Maintenance

A

Regular repair or replacement of components or equipment after a specified interval has passed - without regard for equipment condition or performance

18
Q

What are some interval measures that could be used?

A
  • (Calendar) time
  • Running hours
  • Number of operating cycles
  • Number of starts
  • Distance
19
Q

When is Interval-Based Maintenance normally chosen?

A
  1. Condition-Monitoring is not cost-effective
  2. It is more convenient to do the repair/replacement in conjunction with another activity, e.g. yearly shutdown of the whole plant
20
Q

What are some examples of Interval-Based Maintenance?

A
  1. Replacing an oil filter after 6000 km
  2. Overhauling a pump every 2 hours
  3. Replacing turbine blades after 100 000 running hours
  4. Repairing a starter after 500 starts
21
Q

When does a failure call for Emergency Maintenance?

A

If it has a major impact on production or operation

22
Q

When does a failure not call for Emergency Maintenance?

A

If it’s impact is small and backup equipment is available

23
Q

Why don’t maintenance programs necessarily strive to prevent all failures?

A

It may prove more expensive to pay for expensive condition monitoring techniques or to replace equipment that is still in good condition rather than wait until the failure occurs, so long as the failure does not result in major safety hazers or large financial losses

2A1-6: Plant Maintenance (8 decks)

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